Impressed emblem and method

ABSTRACT

An impressed emblem is disclosed which includes a cover sheet which is used together with heat and pressure to impress a desired pattern on an emblem. The emblem can also be impressed with a pattern and simultaneously heat-sealed onto a desired substrate.

FIELD OF INVENTION

The present invention relates to an engraved cover sheet which whenplaced in mating engagement with an emblem, in the presence of heat andpressure, causes the impression on the cover sheet to be impressed onthe emblem. The present invention further relates to a method forimpressing a desired pattern on an emblem.

BACKGROUND ART

Emblems have been widely used to apply a variety of designs, patterns,numerals, names and logos onto many different types of substrates.Emblems have found particular use on sports jerseys, jackets and thelike. Design emblems incorporating trademark indicia or licensedcharacters have also become increasingly popular.

To add to the design characteristics or trademark indicia of an emblem,prior art techniques have disclosed methods for embossing a desiredlettering or design pattern onto an emblem.

U.S. Pat. No. 5,322,783 discloses a method for heat-embossing asynthetic woven material by use of a heat-resistant distortableintermediate material between the heat-embossing die and the targetmaterial that is subject to high adhesive properties when melted duringthe embossing process.

U.S. Pat. No. 5,298,031 relates to a method for embossing and decoratinga thermoplastic velvet-like fabric. In the '031 patent, a transfer sheetsupporting a thermally-activated decoration is simultaneously passedwith a fabric between two rolls which are under pressure with respect toeach other. At least one of the rolls is engraved so as to causeembossing of the fabric. The passing of the fabric and transfer sheetbetween the rolls is carried out at a temperature sufficient to activatethe decoration and allow the transfer of the decoration to the embossedportions of the fabric.

U.S. Pat. No. 4,581,278 directed to thermo-imprinting of one or moresurfaces, uses a heat-transfer cover and a release layer pigmented, lowmolecular weight polyolefin. The imprint is made by bringing thetransfer layer into contact with the surface of an object while applyingheat.

One significant problem with the prior art methods for emblem impressingis that such methods require tooling a die with the desired impressionand then impressing the emblem with the die. For each individual patternthat is desired, a separate die must then be manufactured that isconfigured in the shape of the desired impression or design. Such amethod of impressing an emblem is both time consuming and veryexpensive. Moreover, since a die must be re-tooled for each new designor logo, this embossing technique can only be utilized for large scaleproduction. In many instances, smaller custom orders for impressedemblems would not be able to afford the cost associated with customtooling a die.

Accordingly, it is an object of this invention to facilitate theproduction and use of impressed emblems. A related object is to reducethe cost of producing suitable impressed emblems and reduce the amountof materials required in conjunction with this method.

An additional object of the present invention is the provision of amethod for simultaneously impressing an emblem with a desired pattern,and heat-fusing the emblem in position on the surface of a substrate,wherein the method utilizes conventional apparatus and is relativelysimple and cost-effective.

Another object of the present invention is to provide a method ofimpressing an emblem without impairing or damaging the underlyingsubstrate.

One more object of this invention is to facilitate marking fabrics withtrademark indicia in a manner that is aesthetically pleasing and costeffective.

A final object of the present invention is to produce an impressedemblem without requiring the expensive step of tooling a die to serve asthe transfer technique for the impressed pattern.

In carrying out the above objects of the invention, a cover sheet forimpressing a pattern on the surface of an emblem is disclosed whichincludes a cover sheet having a base layer and a release coatingthereon, wherein the release coating exhibits an impressioncomplementing the desired pattern, such that when the coating is placedin registry with an emblem and heat and pressure are applied on thecover sheet toward the emblem, the desired pattern is formed on theemblem.

This invention further provides an impressed emblem including an emblemhaving an upper thermoplastic layer and a lower adhesive layer; a coversheet having a base layer and a release coating thereon, wherein thecoating exhibits an impression complementing the desired pattern; andthe upper thermoplastic layer and the release coating being placed intomating engagement with one another such that upon the application ofheat and pressure on the cover sheet and toward the emblem, the upperthermoplastic layer is impressed with the desired pattern.

The present invention further discloses a method of impressing a desiredpattern to an emblem and a method for impressing a desired pattern to anemblem during simultaneous attachment of the emblem to a substrate. In apreferred embodiment the surface of the emblem is embossed or debossedslightly to form indicia, such as a trademark or the like, which islegible within about four feet of a viewer, but not substantiallytherebeyond. This enables a sports numeral, for example, appearing on asports jersey to be identified with a trademark or other message whichdoes not detract from the principle identifying function of the numeral.

This thermal impressing method preferably utilizes a cover sheet, thecover sheet is made up of a base layer with a release coating appliedthereon. The cover sheet has an impression complementing the desiredpattern. The impression can consist of raised surfaces or engraved,grooved or rigid surfaces. To create the impressed emblem, the releasecoating is matingly applied to the emblem, such that, upon applicationof heat and pressure on the cover sheet and toward the emblem, theemblem becomes impressed with the desired pattern. In one embodiment,the same application of heat and pressure used to bring about theimpressing, is simultaneously used to adhere the emblem onto a desiredsubstrate. With this method, the emblem is impressed and adhered to anunderlying substrate, in one step.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a perspective view of an impressed emblem applied to asubstrate;

FIG. 2 is an enlarged view of the impressed lettering of FIG. 1 taken atthe circular area 2 of FIG. 1;

FIG. 3 is a cross-sectional view taken on the line 3--3 of FIG. 2,showing the raised, impressed markings or desired pattern on the emblem;

FIG. 4 is a perspective view of a multi-colored emblem without anyimpressed markings or desired pattern;

FIG. 5 is a cross-sectional view taken on the line 5--5 of FIG. 4;

FIG. 6 is a perspective view of a cover sheet;

FIG. 7 is an enlarged view of the cover sheet of Figure taken at thecircular area 7 of FIG. 6;

FIG. 8 is a cross-sectional view taken on line 8--8 of FIG. 7, showingthe indentations on the release coating;

FIG. 9 is a side view of the platens positioned for placement of theemblem in mating engagement with the cover sheet;

FIG. 10 is a side view of the platens in operative position to applyheat and pressure and effectuate emblem impressing and emblem attachmentonto the substrate;

FIG. 11 is a perspective view of an impressed emblem; and

FIG. 12 is a cross-sectional view taken along lines 12--12 of FIG. 11showing the indentations of the fabric layer.

BEST MODE FOR CARRYING OUT THE INVENTION

The present invention eliminates the expensive production of patternedand three-dimensional emblems and converts a formerly complex,multi-step process into a few simple steps whereby an emblem can beadhered onto a substrate and, at the same time, the emblem may beimpressed with a desired pattern.

The term "impress" as used throughout the specification is definedhereinafter as the act of producing a mark formed by or as if bypressure. The term "impression" as used in the specification is definedas the effect produced by impressing. The term "impressed" or "impress"is thus defined so as to include the production of raised marks such asbosses and engraved marks such as ridges and grooves. Accordingly, animpression is intended to include both raised markings, embossedmarkings above the surface, and engraved or debossed ridges or groovesmade below the surface. Furthermore, the term "complement" or anyvariation thereof such as "complementary," "complementing," or"complemental" is defined as one of two mutually completing parts.

FIG. 1 illustrates one example of an impressed emblem 10. The impressedlettering pattern 12 depicted in FIG. 1 is but one example of the manydesigns, numerals, logos and other indicia which may be impressed on anemblem. In the illustrated example, the impressed lettering pattern 12serves as an aesthetically pleasing trademark identifier. Similarly, itis contemplated that sports garments, in particular, sports jerseys canbe impressed with the NFL or NBA logos to function as a means fortrademark identification in other instances, the impressing canconstitute a desired design pattern. FIG. 2 shows an enlarged version ofthe impressed lettering pattern 12 on the emblem.

In a preferred embodiment, the lettering pattern 12 will be only faintlyor slightly legible, for example, at not more than about four feet fromthe viewer. Thus, the pattern 12 will not detract from the principalidentifying function of the emblem.

As shown in FIG. 3, the impressed emblem 10 of the present inventionincludes an upper thermoplastic layer 14, an upper adhesive layer 16, alower thermoplastic layer 18, a lower adhesive layer 20 and thesubstrate 22 on which the impressed emblem 10 is adhered, as shown inFIG. 1. While FIGS. 1-5 depict an emblem having an upper and lowerthermoplastic layer 14, 18 and an upper and lower adhesive layer 16, 20,this invention is not limited in any way to the depicted emblem. On thecontrary, the emblem shown in FIGS. 4 and 5, is simply one way toassemble a multi-layered emblem where the lower thermoplastic layer 18'is cut to the same shape but a larger size than the upper thermoplasticlayer 14' such that when the two thermoplastic layers are placed one ontop of another, the lower thermoplastic layer 18' extends beyond theperiphery of the upper thermoplastic layer 14' and serves as an outline.The emblem can also be a simple structure having an upper thermoplasticlayer with a lower adhesive layer thereon. Any such variation of anemblem is suitable for purposes of impressing a pattern thereon. Theupper and lower thermoplastic layers 14, 18 or 14', 18' are preferablyone of the following: polyurethane, polyester, polyamide, EVA,thermoplastic styrene butadiene, rubber, and blends thereof. The lowerand upper adhesive layers are preferably either a polyester,polyurethane, or polyamide adhesive or blends thereof.

FIG. 3 further illustrates one possible impressed emblem. FIG. 3 showsan emblem having raised or embossed markings on the upper thermoplasticlayer 14. Again, the present invention includes impressed emblems, bothembossed or raised emblems and debossed emblems having markings belowthe surface.

FIGS. 4 and 5 further depict the differences between an emblem 24 beforeimpressing and an impressed emblem 10. As shown in FIG. 5, the upperthermoplastic layer 14' of the emblem before impressing has asubstantially flat surface when compared to the upper thermoplasticlayer 14 of the impressed emblem 10, the impressions thereon are readilydetectable. FIGS. 4 and 5 also illustrate the emblem itself, in contrastto FIGS. 1-3 which show the emblem 10 on a substrate 22.

FIG. 6 depicts the impressed cover sheet 26 which is used to create animpressed emblem, as shown in FIG. 1. The cover sheet 26 can be eitherengraved or embossed depending on the emblem impression that is desired.If an embossed emblem is desired, a complementary engraved pattern isetched into the cover sheet. Likewise, if an emblem is desired with agrooved ridged pattern, the cover sheet 26 is embossed with thecomplementing pattern. The cover sheet may be impressed with any desiredlogo, lettering or design. One example is the engraved Stahls' letteringpattern 28, depicted in FIG. 6. With the use of a laser-cutting deviceor a precision knife, intricate patterns may be engraved into the coversheet 26 for subsequent embossing on an emblem. With the use of a stamp,the cover sheet 26 can be embossed with raised markings in a desiredpattern. FIG. 7 further depicts an enlarged view of a letter pattern 12which can be impressed on the cover sheet 26.

The engraved cover sheet 26, a cross-section of which is depicted inFIG. 8, comprises a base layer 30 with a release coating 32 applied tothe base layer 30. As can be seen in FIG. 8, the indentations 33 thatare made during the impressing process are confined to the releasecoating 32 so that the base layer 30 is left intact and can be used as asupport means for the release coating 32. Accordingly, if the coversheet 26 is to be engraved, the engraving must be adjusted so as not tocut deeper than the thickness of the release coating 32. The base layer30 of the cover sheet 26 is preferably paper, fabric or plastic.However, if plastic is used as the base layer 30, the plastic must havea melting point that is sufficiently high so that during the impressingand heat-sealing processes, the base layer 30 remains intact. The baselayer 30 is most preferably paper. In a preferred embodiment, therelease coating 32 can be silicone, vinyl, Thermofilm®, or anypolyurethane. Thermofilm® is a registered product of Stahls' Inc.Thermofilm® is a two-layer product wherein the first layer is urethanepigment layer having a polyester adhesive layer coated thereon.

FIG. 9 depicts one method disclosed in this application, wherein anemblem can be impressed with a desired pattern and simultaneouslyattached on a substrate. One particular feature of the method resides inthe step of simultaneously impressing the upper thermoplastic layer 14of the emblem 24 while attaching the emblem 24 to the underlyingsubstrate 22 using heat and pressure. To effectuate the attachmentprocess, as depicted in FIG. 9, heat and pressure are applied usingconventional sealing machines. As shown in FIG. 9, with the use of aheat-sealing device 37 having an upper platen 34 and a lower platen 36with the ability to controllably release heat and apply pressure, asubstrate 22, the emblem 24 and an impressed cover sheet 26 can beplaced one on top of the other. More specifically, as shown in FIG. 9,on a lower platen 36, there is placed the desired substrate 22, followedby the emblem 24. The emblem 24 is placed on the substrate 22 in aposition such that the lower adhesive layer 20, as depicted in FIG. 5,is in mating contact with the substrate 22. Furthermore, the emblem 24is placed so that the upper thermoplastic layer 15 is exposed. Followingthis placement, the impressed cover sheet 26 is superimposed on theemblem 24. The impressed cover sheet 26 is superimposed such that therelease coating 32 is in mating contact with the upper thermoplasticlayer 14 of the emblem 24. It then follows that the base layer 30 of thecover sheet 26 is the layer that comes into contact with the upperplaten 34 when the upper and lower platens 34, 36 are placed in anoperative position, as shown in FIG. 10. The upper and lower platens 34,36 are placed in an operative position for a time sufficient to bringthe lower adhesive layer 20 to its melting temperature so that theadhesive can adhere to the underlying substrate 22. The upper and lowerplatens 34, 36 are further placed in operative position for a timesufficient to impress the upper thermoplastic layer 14 with thecomplement of the desired pattern 28 on the cover sheet 26. Accordingly,the upper and lower platens 34, 36 deliver heat and pressure toward theemblem and the substrate sufficient for the emblem 24 to adhere to theunderlying substrate 22 and simultaneously have the cover sheet 26impress the upper thermoplastic layer 15 of the emblem 24 with thedesired pattern 22 on the surface.

In another embodiment of this invention, a method for impressing adesired pattern on an emblem without at the same time adhering theemblem to a substrate is disclosed. For this method, the emblem furtherrequires the use of a carrier sheet to protect the lower adhesive layer20 of the emblem both prior to, during and following the process ofimpressing the emblem. The carrier sheet is preferably a releasablesheet which is made of paper, fabric or plastic. If the carrier sheet ismade of plastic then the plastic must have a higher melting point thanthe temperature required to impress the emblem. For such a method, againthe impressed cover sheet 26 would be placed in mating engagement withthe upper thermoplastic layer 14 of the emblem 24. Furthermore, thecombination of the impressed cover sheet 26 placed together with theemblem assembly 24 would be sandwiched between the platens 34, 36 forthe application of heat and pressure necessary to effectuate theimpressing process on the emblem.

In yet another embodiment of this invention, a laser-cutting device or aprecision knife can be used to directly engrave or etch the fabric layerof an emblem. As depicted in FIG. 11, the Stahls' lettering pattern 12may be etched into the fabric layer 38 of an emblem. As shown in FIG.12, with this technique, the fabric layer 40 is itself debossed withindentations that constitute the desired pattern.

Suitable substrates 22 on which the emblem 10 can be applied includematerials such as twill, cotton, wools, polyester and syntheticmaterials, such as Gortex and Lycra.

While the best mode for carrying out the invention has been described indetail, those familiar with the art to which this invention relates willrecognize various alternative designs and embodiments for practicing theinvention as defined by the following claims.

What is claimed is:
 1. A cover sheet for impressing a pattern on athermoplastic surface of an emblem, comprising:a base layer; a heatapplication release coating on the base layer; said release coatingexhibiting a heat resistant and pressure resistant debossed or embossedimpression complementing the pattern; and said cover sheet, when placedwith its release coating against and in registry with the thermoplasticsurface of an emblem and heat and pressure are applied on said coversheet and toward the emblem, the pattern is formed on the thermoplasticsurface of the emblem.
 2. The cover sheet in claim 1 wherein said baselayer is selected from the group consisting of paper, fabric andplastic.
 3. The cover sheet in claim 1 wherein said coating is selectedfrom the group consisting of silicone, vinyl and urethane.
 4. The coversheet in claim 1 wherein said coating exhibits an engraved impressionformed by using a laser cutter or a precision knife.
 5. The cover sheetin claim 1, wherein said coating exhibits an impression formed bystamping to boss the complemental pattern on said coating.
 6. A coversheet combination for impressing a pattern on the surface of an emblemwhile affixing it to a substrate, comprising:a cover sheet having a baselayer and a release coating on one face thereof; an emblem having anupper thermoplastic layer and a lower adhesive layer; said releasecoating having an impression complementing the pattern; said emblembeing positioned on the substrate in a location such that said upperthermoplastic layer is exposed; said cover sheet being superimposed onsaid emblem such that said release coating is in mating engagement withsaid upper thermoplastic layer; said cover sheet being heated andpressed toward the substrate and against said emblem to affix saidemblem to the substrate and form the desired pattern on the emblem.